Printed chocolate structures

ABSTRACT

A method for printing a three-dimensional crystalline structure such as a chocolate layer wherein, after printing, the material has a desired crystal structure and a plurality of non-random cavities. An embodiment can include printing a liquid first layer of material with a printer onto a second layer of material having a crystal structure. Subsequently, the printed liquid first layer is processed to solidify the first layer. During the processing of the printed liquid first layer, the second layer functions as a crystal seed layer through physical contact with the printed liquid first layer and the second layer crystallizes with the crystal structure. In some embodiments, confections may be formed from high-quality chocolate, where the confection has a reduced caloric content with acceptable mouthfeel. In other embodiments, a confection may have a previously unrealized mouthfeel and taste.

FIELD OF THE EMBODIMENTS

The present teachings relate to the field of forming crystal structuresand more particularly to methods for printing a layer having a desirablecrystal structure, for example a chocolate layer having a desirabledegree of crystallization or temper.

BACKGROUND OF THE EMBODIMENTS

Various compounds can have different crystal structures depending onfactors such as temperature. For example, chocolate, and moreparticularly cocoa butter within chocolate, can generally have one ofsix crystal structures depending on how it is produced. The crystalstructures range from type I to type VI with each crystal type having adifferent melting point. Generally accepted melting points of cocoabutter crystal types are as follows: type I: 17° C.; type II: 21° C.;type III: 26° C.; type IV: 28° C.; type V: 34° C.; type VI: 36° C. TypeVI crystals require an extended duration of time (a matter of months) toform and are not found in typical chocolate.

Tempering of chocolate during production is necessary to produce aproduct with as many type V crystals as possible, which is the cocoabutter crystal structure typically used for consumer chocolate. Totemper chocolate to produce type V crystals, the chocolate can be heatedto a temperature which is higher than the type IV crystal meltingtemperature, for example 31° C. to 32° C. for a duration of time whichis sufficient to melt the type I to type IV crystals, then cooled.During the cooling, the type V crystals that remain function ascrystallization nuclei, around which other type V crystals will form.

In another method of forming type V cocoa butter crystals, a solid seedchocolate having a preponderance of type V crystal structures isdispensed into a melted chocolate which is at a temperature between thetype IV and type V crystal melting point. The type V crystals in thesolid chocolate function as crystallization nuclei for the moltenmaterial such that the melted chocolate crystallizes into a type V cocoabutter crystal structure.

Quality chocolate with a type V crystal structure has desirablecharacteristics, such as a shiny surface, a firm texture, a good snap, amelting point which is above typical ambient temperatures but generallyaround human body temperature and a texture and appearance which willnot degrade over time.

Attempts have been made to fashion three dimensional designs withchocolate using a chocolate dispenser (printer) with a controlledplacement of material. This chocolate printing may include dispensing anin-temper material. However, due to high viscosity of in-temperchocolate, the material must be extruded, which requires a largeextrusion nozzle size that has a large resolution and is thereby unableto form well-defined, small resolution features. Heating chocolate to ahigher temperature to achieve a lower viscosity can cause the chocolateto lose temper. Thus current 3D chocolate printers cannot print fine 3Dstructures which have a high percentage of cocoa butter type V crystalstructures. Current methods of chocolate printing can result in printedchocolates that lack the required resistance to elevated temperaturesand other desirable properties of snap, surface finish, and texture.

Additionally, current chocolate processing is limited by the techniquesused in the processing. For example, a chocolate confection mightcontain a flavored center and an outside coating of solid chocolate.Current variety in texture consists of using fillings such as a smoothganache mixed with nuts or layering different fillings.

Further, consumers take cues on how much to eat largely based on visualappearance of the product before it is consumed rather than on theactual caloric value of the product itself. Lowering a product's caloriecount by removing fat and/or sugar may result in a flat and unsatisfyingconsumer experience. Hollow chocolate does not produce a desirableconsumer experience, as a bite simply breaks the outer shell andprovides no subsequent bite resistance. Aerated chocolate formed byinjecting gas at high pressures into the molten chocolate has aconventional external form factor and reduces overall calorie count.However, the randomized air bubbles provide a less-than-desirabletexture as the product is consumed. Further, the randomized bubbles inthe internal structure of the uneaten portion of the product after aninitial bite are not visually appealing.

New production techniques and the resulting new confection designs wouldbe desirable.

SUMMARY OF THE EMBODIMENTS

The following presents a simplified summary in order to provide a basicunderstanding of some aspects of one or more embodiments of the presentteachings. This summary is not an extensive overview, nor is it intendedto identify key or critical elements of the present teachings nor todelineate the scope of the disclosure. Rather, its primary purpose ismerely to present one or more concepts in simplified form as a preludeto the detailed description presented later.

In an embodiment, a method for printing an edible confection having athree-dimensional crystalline structure may include printing a liquidfirst layer of material with a printer onto a second layer of materialhaving a crystal structure to form a plurality of walls, wherein each ofthe plurality of walls physically contacts the second layer of materialand extends from the second layer of material at an angle, processingthe printed liquid first layer to solidify the plurality of walls, andprinting a liquid third layer of material with the printer onto thesecond layer of material to form a ceiling that physically contacts theplurality of walls to form a plurality of non-random cavities within theconfection, wherein the ceiling comprises a surface that intersects asurface of the second layer of material at an angle.

In another embodiment, a confection may include a plurality of chocolatewalls, wherein each chocolate wall has a thickness of between 5micrometers and 10 millimeters, a plurality of non-random cavitiesformed at least partly by the plurality of chocolate walls, and an outershell that seals the plurality of non-random cavities within theconfection.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the presentteachings and together with the description, serve to explain theprinciples of the disclosure. In the figures:

FIGS. 1-4 are cross sections of a first embodiment of the presentteachings for printing a three-dimensional structure having a desiredcrystal structure;

FIG. 5 is a cross section of a second embodiment of the presentteachings for printing a three-dimensional structure having a desiredcrystal structure;

FIGS. 6-8 are cross sections of a third embodiment of the presentteachings for forming a three-dimensional structure having a desiredcrystal structure;

FIG. 9 is a cross section depicting formation of a confection accordingto an embodiment of the present teachings; and

FIGS. 10 and 11 are cross sections depicting confections according toembodiments of the present teachings.

It should be noted that some details of the FIGS. have been simplifiedand are drawn to facilitate understanding of the present teachingsrather than to maintain strict structural accuracy, detail, and scale.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to exemplary embodiments of thepresent teachings, examples of which are illustrated in the accompanyingdrawings. Wherever possible, the same reference numbers will be usedthroughout the drawings to refer to the same or like parts.

As used herein, unless otherwise specified, a “printer” encompasses anyapparatus that performs a deposition of a material onto a substrate.While the present teachings are described herein with reference to aprinter that prints an edible material, specifically a chocolateprinter, it will be understood that any edible confectionery material ornon-edible material which is manufactured to include a particularcrystal structure and which is capable of crystallizing through the useof a crystallization nucleus or crystal seed may advantageouslyincorporate an embodiment of the present teachings. Additionally, forpurposes of the present description, the work “ink” is used to refer toany material that is dispensed by the printer, and can include an ediblematerial (e.g., chocolate) and/or an inedible material, for example anyelement, molecule, compound, or mixture that falls within the scope ofthe present teachings. Further, unless otherwise specified, a “molten”material includes a material that is in a non-solid form, for exampleliquid or semi-viscous.

An embodiment of the present teachings can include printing a firstmaterial which has an undesired crystal to result in a second materialthat has a desired crystal shape. The final structure may be anon-edible material used for commercial or consumer purposes. The finalstructure may also be an edible confection having a desired crystalshape such as a chocolate structure having a three dimensional (3D)shape. The text below describes the present teachings with regard to achocolate layer, but it will be understood that the present teachingsmay apply to any edible or inedible materials. In an embodiment, thecompleted 3D structure may have a desirable crystal configuration, suchas a type V cocoa butter crystal structure. An untempered moltenchocolate layer can be dispensed or printed upon a tempered chocolatebase layer such as a solid chocolate base layer having a type V cocoabutter crystal structure. As the molten chocolate is printed onto thebase layer, the solid chocolate base layer functions as a crystal seedlayer or crystallization nucleus through physical contact with theprinted layer. As the molten chocolate cools, its crystal structureconforms to that of the base layer to result in a 3D structure having adesired cocoa butter crystal structure (i.e., a desired temper).

An embodiment of the present teachings can include a method andin-process structures which can be formed during an embodiment of thepresent teachings, for example as depicted in FIGS. 1-4 and described inthe accompanying text.

FIG. 1 depicts a substrate 10 and a base layer 12 which overlies and/orcontacts the substrate 10. The substrate 10 can include a metal layer, apolymer layer, a plastic layer, etc., and may be electrically and/orthermally conductive. The base layer 12 can be a chocolate base layerhaving a particular crystal structure such as a type V cocoa buttercrystal structure. In an embodiment, the base layer 12 can have athickness of between about 1.0 micrometer (μm) and about 10.0millimeters (mm), or between about 1.0 μm and about 3.0 mm, or betweenabout 1.0 μm and about 1.0 mm. It is contemplated that a layer thinnerthan 1.0 μm may be sufficient, and the base layer 12 may include a baselayer in dry powder form. The base layer 12 should be sufficiently thickto cover the substrate 10 at least where a 3D structure will be printed.For example, the base layer 12 can cover the entire upper surface of thesubstrate 10, or a perimeter of the substrate 10 can be exposed around acentrally located base layer 12. A base layer 12 which is insufficientlythick can include undesirable gaps or may fail to retain its crystallineform when hot ink is printed thereon. In certain embodiments of thepresent teachings, an excessively thick base layer 12 may not allow forprocessing as described below.

In an embodiment, the base layer 12 can be applied to the substrate 10as a molten layer having a type V crystal structure which coats at leasta portion of an upper surface of the substrate 10. After application,the molten base layer 12 can be cooled such that it solidifies with atype V crystal structure. In another embodiment, the molten base layer12 applied to the substrate 10 can have a first crystal structure, forexample that is not type V (which may be no crystal structure, a typeI-type IV crystal structure, a type VI crystal structure, or mixturesthereof), and then tempered after placement on the substrate 10 to havea desired second crystal structure, such as a type V crystal structure.Tempering of the first crystal structure to the second crystal structurecan be performed by heating the material on the substrate 10, thencooling the material.

In an embodiment, a thermally conductive substrate 10 can be activelyheated with an optional powered internal heat source 14 such as a coilthat is electrically connected (i.e., electrically coupled) to power 16and ground 18, which is heated to a temperature or a series oftemperatures in order to temper the liquid, solid, powdered, orgranulated base layer 12, or for other uses as described below. Inanother embodiment, structure 14 can represent an optional poweredinternal cooling source 14 such as a cooling coil which is cooled tomore quickly solidify a melted base layer 12 to decrease manufacturingtime. In another embodiment, element 14 can represent both an optionalheat source and an optional cooling source, so that the substrate 10 canbe heated and cooled as desired.

After forming the base layer 12 having a desired crystal structure, aprinter or printhead 20A is used to deposit a first 3D structure layer22 onto the base layer 12 as depicted in FIG. 2. It will be apparent toone of ordinary skill in the art that the structures such as printer20A, substrate 10, etc., depicted in the FIGS. represent generalizedschematic illustrations and that other structures or elements can beadded or existing structures or elements can be removed or modified. Inan embodiment, the printer can include a reservoir 24A which contains asupply of material 26 and, in this embodiment, a plurality of nozzles28A through which the material 26 is printed or extruded under pressure.For printing of chocolate material 26, the chocolate can be heated to atemperature that is sufficient to soften or melt all of the cocoa buttercrystals, for example to a temperature of above 40° C., for examplebetween about 40° C. to about 60° C. Additionally, chocolate at thistemperature has a viscosity that is sufficiently low so that thechocolate 26 is ejected or flows easily through the printer 20A and outof the nozzle 28A. However, heating chocolate to this temperature for alow viscosity material causes the chocolate to lose its temper, as thetemperatures required to generate the desired in-temper crystals forms amaterial that is very thick and does not flow with sufficient ease forprinting.

Printer 20A may be, for example, a drop-on-demand (DOD) ink jet printer.Ink, for example chocolate, can be ejected as a plurality of droplets 29through the nozzles using a transducer such as a piezoelectric elementwhich deflects a diaphragm as known in the art. The printer 20A may be aprinter other than a DOD ink jet printer, such as an extrusion printer,a solid ink printer, or a printer which uses other ink printingtechnology. In the case of an extrusion printer, for example, droplets29 depict extruded material 26. In the case of a DOD printer, forexample, the droplets 29 can be simultaneously ejected from theplurality of nozzles 28A as individual droplets but can be printed withsufficient density so as to form a uniform first layer 22 having adesired thickness.

As the first layer 22 is deposited onto the in-temper chocolate baselayer 12, the base layer 12 seeds crystallization in the first layer 22.As the first layer cools, its crystals take on the crystal configurationof the base layer 12 to form an in-temper 3D first layer 22. Thesubstrate 10 may be cooled using a powered internal cooling source 14 todecrease cooling time. As will be understood by one of ordinary skill,the first layer 22, as well as subsequent layers as described below,must be cooled slowly enough to allow sufficient crystal growth orformation. Cooling the material too quickly may not allow sufficienttime for the nucleating crystals to grow throughout the thickness of thenew drop or line of material using the crystal structure of the baselayer 12 as a crystal seed layer. In another embodiment, the substrate10 can be slightly heated to increase cooling time of the chocolatefirst layer 22 to maximize crystal formation. Additionally, ambient airaround the cooling surfaces can be actively or passively dehumidified toreduce or prevent water contamination of the surface. In an embodiment,the ambient air around the cooling surfaces is dehumidified to ahumidity of 50% or less.

Subsequently, a 3D second layer 30 can be printed using the printer 20Bas depicted in FIG. 3. FIG. 3 depicts a different printer 20B forillustration purposes. In contrast to printer 20A having a plurality ofnozzles 28A, printer 20B includes a single nozzle 28B which prints allmaterial. Printer 20B can be a single nozzle DOD printer, an extrusionprinter, etc. Generally, the same printer may be used to print each ofthe printed layers.

Because the crystal structure of the 3D first layer 22 takes on thecrystal structure of the base layer 12, the second layer 30 takes on thecrystal structure of the 3D first layer 22 through physical contact,such that the first layer 22 function as a crystallization nucleus forthe second layer 30.

Similarly, any number of additional layers 32 can be printed to build ormanufacture a desired 3D shape as depicted in FIG. 3. A delay can beimplemented after printing each layer so that a printed layersufficiently cools and crystallizes before applying a subsequent layer.In an embodiment, the base layer 12 can have a first color, the firstlayer 22 can have a second color that can be the same or different fromthe first color, and any of the additional layers 32 can have a thirdcolor that is the same or different than the first color and/or thesecond color.

After the 3D structure 40 has been completed, it may be removed from thebase layer 12 as depicted in FIG. 4. In an embodiment, the 3D structuremay be removed from the base layer 12 using a blade, which may or maynot be heated, to separate the 3D layer 40 from the base layer 12. Inanother embodiment, the optional heat source 14 within the substrate 10can be heated sufficiently to soften the base layer 12, and the 3Dstructure 40 can be lifted from the base layer 12 using mechanicaltechniques or by a human operator. In yet another embodiment, a verythin base layer 12 or a base layer 12 in powder or granulated form isused such that regions of the base layer 12 which do not have anoverlying layer of printed material 22, 30, 32 are left behind on thesubstrate 10 when the 3D structure is removed.

It is contemplated that, generally, the base layer 12 may remain as apart of the completed 3D structure. If the base layer 12 is to remain aspart of the 3D structure, the base layer 12 can be formed on a releaselayer 50 to facilitate removal of the structure including layers 12, 22,30, and 32 from the substrate 10. In an embodiment, for example whenprinting a chocolate layer as the ink, the release layer 50 can be aparchment paper or another release layer. As depicted in FIG. 5, therelease layer 50 is interposed between the substrate 10 and the baselayer 12 to facilitate removal of the 3D structure 40, including thebase layer 12, from the substrate 10.

In another embodiment in which the base layer 12 is not part of the 3Dstructure, the release layer 50 as depicted in FIG. 5 can be placed ontothe substrate 10 prior to formation of the base layer 12, or the baselayer 12 can be formed on the parchment paper 50, and the assemblyincluding the parchment paper 50 and the base layer 12 can be placedonto the substrate 10. Subsequently, the 3D structure 40 is formedaccording to the present teachings. Next, the parchment paper 50 withthe overlying layers 12, 40 are removed from the substrate 10.

In another embodiment, after forming the 3D structure as depicted inFIG. 5, the parchment paper 50, base layer 12, and 3D structure 40 canbe lifted off the substrate 10. Due to the low adhesion of the parchmentpaper 50, the paper 50 can be peeled off the base layer 12. Next, thebase layer 12 can be abraded away using one of the techniques describedabove, or melted away, to leave the 3D structure 40.

Another embodiment of the present teachings is depicted in the crosssections of FIGS. 6-8. As depicted in FIG. 6, a base layer 60 is formedon a substrate 10 to a sufficient thickness to function as a seed layerfor one or more subsequent layers deposited using a printer 20A, such asa DOD printer. In this embodiment, the base layer 60 is a seed layer incrystal powder or granule form. After layering the substrate 10 with thepowder base layer 60, the printer 20A prints a desired first layer 62which includes portions 62A and 62B by ejecting a plurality of inkdroplets 29 from the nozzles 28A in accordance with other embodiments ofthe present teachings. Because the printer 20A is a drop-on-demandprinter, various different shapes as desired can be printed. In thisembodiment, the base layer 60 has a desired crystal structure while thedroplets 29 are heated for printing, and have a crystal structure whichis different from the base layer 60. Through contact with the base layer60, which functions as a crystal seed layer, the printed first layer 62takes on the crystal form of the base layer 60.

Next, a second layer of crystal powder 70 is applied over the substrate10 as depicted in FIG. 7. The second layer of crystal powder 70 caninclude the same material as base layer 60. Subsequently, a secondprinted layer 72 including portions 72A-C is printed over the crystalpowder 70. Through contact with the crystal powder 70, portions 72A and72C form with the crystal structure of the crystal powder 70 by usingthe crystal powder 70 as a crystallization nucleus. Portion 72B contactsboth the crystal powder 70 and the first layer 62B, and thus forms withthe crystal structure of the powder 70 and the first layer 62B.Additional powder layers can be deposited and additional layers can beprinted as desired to form a 3D structure.

Next, the powder layers 60, 70 are removed. The powder layers 60, 70 canbe removed by any sufficient process, for example by blowing the powderlayers away using an air stream, by vacuuming the layers away, byrinsing, or removed using some other removal process. After the crystalpowder layers 60, 70 are removed, the desired 3D structure as depictedin FIG. 8 remains.

By printing chocolates with a drop-on-demand printhead, a much greatervariety of structures is possible. One textural option includes theformation of cavities (i.e., chambers) 90 within the chocolate structure92 as depicted in FIG. 9 to provide previously unrealized “mouthfeel”and taste. These cavities 90 may be controlled and formed by printingstructures such as columns (i.e., walls, pillars) 94, a base (i.e.,floor) 12, ceilings 96, ceilings, etc., where the floor(s) andceiling(s) intersect the walls. The floors, walls, and ceilings may beformed on the order of sub-millimeter to several millimeters thick. Inan embodiment, each cavity may have a cross sectional dimension (lengthand/or width) of between about 5 μm and about 10 mm, or between about 10μm and about 1.0 mm, or between about 20 μm and about 100 μm. Thesecavities 90, which may have a cubic, rectangular cuboid, tetrahedral,octahedron, or other three-dimensional polyhedron shape, may beoptionally filled with any desired chocolate or non-chocolate fillingmaterial 98A-98C, and different cavities 90 may be filled with the sameor different materials in the same confection piece, and unfilled 100cavities can be combined with filled cavities to provide a uniquemouthfeel. A plurality of fillings 98A-98C can be distributed bylocation in the confection if the filling consistency lends itself toprinting, or the filling 98 can be dispensed using a differentdispensing method. If a printer or printhead 20A is used to dispense thefilling 98, the drop-on-demand printhead that prints a chocolate mesh(i.e., web, matrix, or lattice) 94-98 may be used, or a differentdrop-on-demand printhead having a different form factor such as largernozzle sizes may be used. In addition, structures that are neitherfilled nor totally closed can be utilized, for example to alter andcustomize the experience of eating. Variety in the experience typicallyincreases a consumer's pleasure and can extend the time of theconsumer's interest from the first bite through the entire process ofeating.

FIG. 9 depicts a confection 102 during printing. At a first stage 102A,a DOD printer 20A prints walls 94 onto a floor 96 that has a desiredtemper. Using the floor 96 as a crystallization nucleus, the walls 94,printed at a temperature sufficient to melt the chocolate to a flowableand printable state as discussed above, which crystallizes duringcooling through contact with the floor 96. In a second stage 102B, anoptional filling 98A may be dispensed into the cavities 90, either byprinting using DOD printhead 20A, a different DOD printhead, or usinganother technique. In a different embodiment, the cavities remainunfilled. After dispensing optional filling 98A, a ceiling 96 may beprinted using the DOD printhead 20A. Subsequently, additional layers maybe formed by continuing the process to form a completed confection 102C.A confection may be formed layer-by-layer to provide any number ofdesired layers.

Various arrangements of walls and cavities are contemplated, some ofwhich are depicted in the cross section of FIG. 10. For example, for asingle confection 104, the wall may be solid across the entire level(i.e., no cavity), for example as depicted in Level 1 (L1) of FIG. 10,or a level may be entirely hollow (i.e., no walls other than theexterior) as depicted in level 4 (L4). Further, any walls (and thus thecavities) may be distributed symmetrically across the level as depictedin level 2 (L2), or the walls may be asymmetrically distributed acrossthe level as depicted in level 3 (L3). As further depicted, the wallsmay have different thicknesses as well as different configurations. Forexample, the walls in L2 are three times the thickness of the walls inL3. If the walls are formed across an entire width of the confection asdepicted in L1, then more bite resistance will be provided in thatdirection. If the walls are only partially formed across the width ofthe confection as depicted in L2 and L3, or the level is hollow asdepicted in L4, then the structure will more readily collapse and theconfection will provide less bite resistance. By using the selectiveformation of walls and floors/ceilings, the collapse of the structure oninitial bites may be engineered to provide a varying consumerexperience. Various parts of the confection can be engineered withdirectional structures, such as oblique walls of equal or varyingthicknesses, walls that extend at an angle from a floor or ceiling, andvarious angles (not individually depicted for simplicity) that vary theexperience within even a single bite.

As discussed above, consumers take cues on how much to eat largely basedon visual appearance of the product before it is consumed rather than onthe actual caloric value of the product itself. Lowering a product'scalorie count by removing fat and/or sugar may result in a flat andunsatisfying consumer experience. Hollow chocolate does not produce adesirable consumer experience, as a bite simply breaks the outer shelland provides no subsequent bite resistance. Aerated chocolate formed byinjecting gas at high pressures into the molten chocolate has aconventional external form factor and reduces overall calorie count.However, the randomized air bubbles provide a less-than-desirabletexture as the product is consumed. Further, the randomized bubbles inthe internal structure of the uneaten portion of the product after aninitial bite are not visually appealing.

In an embodiment of the present teachings, a high quality confection maybe engineered and manufactured with a drop-on-demand printhead to have alower calorie count than other confections while maintaining an orderedand/or non-random internal structure, as well as an external form factorand mouthfeel that are similar to conventional, non-aerated chocolate.The internal structure is non-random, at least because the confectionfloors, walls, and ceilings are designed prior to printing andprogrammed into the printer, which prints the designed confectioninternal structure during printing. A mesh of crystalline chocolate withrelatively thicker vertical walls parallel to the bite direction andrelatively thinner horizontal supports perpendicular to the bitedirection, for example similar to level L2 in the confection 104 of FIG.10 (with the bite direction being vertical with respect to FIG. 10), maybe printed to provide a confection that provides a suitable mouthfeelwhile reducing the number of calories. Variations of the size andinterconnected chocolate can be engineered to provide different anddesirable mouthfeels. Thin structures, such as the walls in L3, willcollapse more easily, while thick structures, such as L1 and the wallsof L2, can be designed to provide significantly more bite resistancethat mimics a conventional chocolate while providing fewer caloriesthrough the incorporation of ordered space within the chocolate. Thusdifferent chocolates can be designed to behave and feel differently inthe mouth.

Similarly, the length of individual segments of chocolate within theinternal structure will affect mouthfeel. Hollow space above or below asegment, such as L4 in FIG. 10, will collapse from a bite before thesegment can provide significant resistance. Long segments such as L1 canprovide resistance sooner in a bite, while shorter ones such as L2provide resistance only after all the hollow spaces have collapsed orbeen filled with chocolate from a different level as the bit reduces thesize.

Another potential benefit of ordered, non-random structures within thechocolate may be to provide increased surface area. This provides moreopportunities for the release of volatile compounds such as aromaextracts of cocoa beans, for example, 2- and 3-methylbutanoic acid,acetic acid, 3-methylbutanal, 4-hydroxy-2,5-dimethyl-3(2H)-furanone, 2-and 3-methylbutanoic acid, 3-methylbutanal and phenylacetaldehyde,4-hydroxy-2,5-dimethyl-3(2H)-furanone, 3-methylbutanoic acid, ethyl2-methylbutanoate, and 2-phenylethanol, and combinations of two or moreof these. Additionally, ordered, non-random structures within thechocolate may allow saliva to better mix with the confection. Either ofthese uses may potentially enhance the intensity of the flavor. Further,a plurality of very fine chocolate whiskers on the order of 100 micronsthick dispensed into the internal confection mesh during manufacture ofthe chocolate may be included to extend into the gaseous volatilecompounds. The plurality of whiskers provide a very high surface areawith a small amount of material, potentially greatly enhancing therelease of volatile compounds once the outer surface of the chocolate isbroken. Chocolate whiskers may be printed to have a diameter of betweenabout 10 μm and 30 μm, for example about 20 μm, and a height of betweenabout 5 mm and about 20 mm, for example about 12 mm.

Variable forms mentioned in previous examples, including walls ofdifferent target thickness and target lengths, can be provided within asingle chocolate. This may allow a single confection to providedifferent mouthfeels depending on the orientation of the confectionduring a bite by the consumer. If long wall segments are only providedin one direction but across the whole confection, then biting parallelto that direction provides significant resistance, while bitingperpendicular provides much less resistance. So a consumer can beencouraged to experience the confections in different ways depending onhow the confection is oriented relative to the teeth. Another variationmay include manufacturing walls of different thicknesses or lengths indifferent parts of the confection. Thin walls toward the outer portionof the confection will collapse easily on an initial portion of a bite,while thicker walls toward the middle of the confection will providesignificant resistance as the bite is completed. Thus the mouthfeelprovides low resistance at first but will increase significantly laterin the bite.

Chocolate comes in many different states depending on how it isprocessed and its origin (variety of tree, growing location,fermentation, drying, roasting, alkalization, additional ingredients andconching. In an embodiment, these different varieties can beincorporated as separate homogeneous structures (as opposed to simplymixing different varieties in a heterogeneous mixture) within a singleconfection such as a candy bar to release unique volatile profiles fromdifferent parts of the candy bar. For example, these homogeneousvolatile profiles can be stored in different cavities within thechocolate bar (for example, as depicted in FIG. 9) by making the wallssurrounding those cavities out of a particular variety of chocolate. Inan embodiment, an inexpensive chocolate type, for example a chocolatethat has been conched for a minimal amount of time, may form some wallsof the confection, for example L2 in FIG. 10, while an expensivechocolate, for example a chocolate that has been conched for up to 72hours, may be used for other layers such as L3, such that the expensivechocolate aromatics dominate. In an embodiment, an inexpensive chocolatesubstructure that forms the interior mesh may be coated with anexpensive chocolate shell.

As discussed above, any open mesh structures described above can befilled, for example by injecting a fluid or viscous material 98 into thewalled receptacles or cavities. A filling will change the mouthfeel ofthe chocolate. Partially filled cavities will behave differently fromfully filled ones, and cavities filled with a viscous but still liquidfruit flavor will be experienced differently from ones filled with solidbut soft materials such as a ganache. Other confections may includedifferent fillings that are individually (separately) encapsulatedwithin a mesh and enclosed within the interior of the confection. Thefillings may be added during confection manufacture by printing a floorand vertical walls to form a plurality of cavities, dispensing adifferent filling, or the same filling, within each cavity, printing aceiling over the one or more fillings to fully encapsulate the filling,and then optionally forming additional cavities and fillings over theinitial structures to construct a confection layer-by-layer. The regionswhere the chocolate is printed may be contiguous to previouslyhardened/crystalized chocolate to result in the proper crystalline formusing the previous chocolate material as a crystallization nucleus.

In an embodiment, horizontal ceilings over hollow cavities may be formedby slightly overlapping a chocolate drop such that it physicallycontacts a previously formed and cooled drop. This may result in aconfection such as 140 depicted in FIG. 11 having an angled ceiling 142connected to vertical walls 144, wherein a surface of the angled ceiling142, for example a curved or generally planar surface, intersects asurface of the vertical wall 144, for example a curved or generallyplanar surface, at an angle of greater or less than 90°. In anotherembodiment, such as confection 112 in FIG. 11, the formation of ahorizontal ceiling 124 having a planar surface that contact a planarsurface of a vertical wall 122 using this technique is alsocontemplated. In another embodiment, a plurality of vertical walls 94may be formed as depicted in 102A of FIG. 9, and then the structure 102Amay be rotated, for example by 90° or another angle, such that theceilings 96 are formed in a more vertical direction and the wallsintersect the ceiling at 90°, or between about 85° and about 95°. Afterformation of at least part or all of the ceiling 96, the structure maybe rotated back into the orientation of 102A to form the walls 94 of thenext level on the ceiling 96.

Final closing of the internal mesh structure may be performed in severalways. For example, if the fillings are dispensed by printing them intothe cavities of the mesh using a DOD printhead, the openings may beclosed by printing chocolate around the opening using a DOD printhead asdepicted in FIG. 9, allowing each chocolate drop to be physicallyconnected to previously printed chocolate so that proper crystallizationoccurs. In an alternate embodiment, if extra chocolate is printed aroundan opening, for example to inject a filling, then the chocolate may bere-melted to a temperature below the tempering point to allow thechocolate to spread and close the opening. In another embodiment, aproperly tempered chocolate piece may be placed to cover the openingbefore a printed melted region around the opening has solidified. Inanother embodiment, the entire structure may be coated by properlytempered chocolate by conventional methods such as dipping or pouring.

It is contemplated that substances including volatile gas compounds suchas fruity, savory, spicy, coffee, etc., esters, for example methylbutanoate, ethyl butanoate, methyl hexanoate, and ethyl hexanoate forcoffee flavors, β-damascenone for an aroma like cooked apples,2-furfurylthiol for a sulfury or roasty flavor,2-isobutyl-3-methoxypyrazine for an earthy flavor, guaiacol for a spicyflavor, 2,3-butanedione for a buttery flavor, and4-hydroxy-2,5-dimethyl-3(2H)-furanone for a caramel flavor, amongothers, may be incorporated into the chocolate cavities of a mesh tomaximize a contribution of odor to the taste sensation that isexperienced while contributing little to the caloric content of theconfection. These volatile compounds may be incorporated into theconfection by manufacturing the confection in a closed (i.e., sealed)cavity filled with the volatile gas. The inclusion of volatile compoundscan be increased by chilling the cavity during manufacture to form aconcentrated gas incorporated into the internal mesh of the confection.After dispensing the filling into the cavity, either by DOD printing orsome other dispensing technique, the cavity may be sealed by printing aceiling to prevent outgassing of the volatile compound. In anotherembodiment, the volatile compounds may be trapped within other edibleliquid or viscous carrier materials and dispensed into one or morecavities within the confection as a filling.

When including layers of filling, the top of the filling itself is not anucleation site. These regions may be bridged by properly temperedchocolate by printing out from a wall of previously printed, properlytempered chocolate that will nucleate the subsequently printed ceilingthat seals the filling within the chocolate mesh. Untempered chocolateon the outside of a confection is undesirable, as chocolate that is notproperly tempered lacks snap, shine, and tends to melt at lowertemperatures, for example when handled. However, these qualities are notnecessarily detriments for structure within the interior of aconfection. Printing non-tempered chocolate structures over fillingswithout connecting to nucleated regions while printing a properlytempered chocolate on the outside may result in a desirable confectionthat has a soft, quickly melting interior.

In an embodiment, different fillings may be provided on different layersof a confection. For example, fillings may be varied from the inside tothe outside of a confection, or from one side to another. This wouldallow, for example, a bar of chocolate to have encapsulated flavoringsthat vary from a first end of the confection (such as a candy bar) to asecond end opposite the first end, or a confection that has segments,for example segments that may be physically separated by the consumerprior to eating, that vary by flavor.

In another embodiment, the 3D printing embodiments of variousembodiments may be used to form external structures with differenttextures. In other words, some of the pillars/walls/cavities may be onthe external surface of the confection. These would allow a consumer toplace the confection in their mouth and experience the textural varietywithout chewing. Besides being decorative, these structures, ifsufficiently tall, might significantly change the eating experience. Forexample, for only a moment after putting the confection into the mouth,only the tops of the structures would melt, yet saliva would interactwith a greater surface area to produce a more intense flavor. Overall,the melting of the pillars, texturally, would be noticeably different tothe tongue, which would initially contact the pillars in fewer places.Because of the open structure, the pillars may be brought up to mouthtemperature more quickly and thus melts more quickly than will a solidblock of chocolate of the same volume.

Various confection configurations printed using a DOD printer or anextrusion printer according to a method discussed above are depicted inthe cross sections of structures 110, 112, 114, and 140 in FIG. 11. Forexample, confection 110 includes an outer shell 116, a plurality ofvertical walls (parallel with respect to the bite direction) 118, and aplurality of hollow cavities 120, although it is contemplated that eachcavity 120 may include the same or different fillings. In thisembodiment, the confection does not include horizontal ceilings internalto the confection. The vertical walls may be formed from differentchocolate types, or the same chocolate type, and the outer shell 116 maybe formed from the same chocolate type, or a different chocolate type,from the walls 118. The vertical walls of confection 110 extend from thefloor to the outer shell 116, and each cavity 120 exposes both the floorand the outer shell 116 within the confection (i.e., the space withinthe cavity contacts the floor and the outer shell, or connects the floorto the outer shell with the space within the cavity). Confection 112includes an outer shell 116, a plurality of vertical walls 122, aplurality of horizontal walls 124, and a plurality of hollow cavities126 that form a mesh, although the cavities may be filled with the sameor different fillings. The cavities 126 are irregular in shape betweenadjacent levels, and the outer shell seals the plurality of cavitieswithin the confection. Confection 114 includes a particular arrangementof fillings, including a first filling 128, a second filling 130 that isdifferent from the first filling 128, and a third filling 132 differentfrom the other two fillings 128, 130, and a fourth filling 134 differentfrom the other three fillings 128, 130, 132. The first filling 128 isonly located at the top, while the second filling 130, located at thelower exterior portion of the confection 114, surrounds the third 132and fourth 134 fillings that are located in the center of the confection114. Confection 140 depicts angled ceilings 142 connected to verticalwalls 144 and a plurality of hollow cavities, which may also be filled.

Thus the present teachings can result in a printed 3D structure, forexample a chocolate structure that has a desired crystalline structure.In the case of chocolate, the 3D structure can have a desirable temper,for example a type V cocoa butter crystal structure. An in-temper baselayer can be used as a crystallization nucleus or crystal seed for aprinted chocolate layer. The base layer can be formed mechanicallywithout the use of 3D printing. The base layer should be sufficientlythick so as to prevent complete melting to the point of losing itscrystalline structure when a drop of chocolate or a chocolate strip atelevated temperatures is printed on top. This base layer then functionsas a crystal seed to nucleate crystallization of the chocolate printedon top in the desired form. Subsequent drops or strips of chocolate willthen be nucleated by the previous drops in the proper crystal form.

The chocolate in-temper base layer serves a number of purposes. First,by acting as a nucleation site, it accelerates the rate ofsolidification of the chocolate printed thereon. Second, the chocolatesproduced using the printer can be in temper. Third, because the printedchocolates are in temper, they have the desirable characteristicsassociated with in-temper chocolates, such as being more stable with ahigher melting point than untempered chocolates, a desirable snap, and ashiny surface.

For use with materials other than chocolate, it is contemplated that aliquid material printed with a non-desirable crystal structure can beprocessed, for example by heating, to remove (evaporate) one or moresolvents or other thinning component and to solidify the liquid materialto form a solid layer. As the solvent is removed the liquid printedmaterial is seeded to a desired crystal structure by the base layer asthe liquid printed material solidifies. For application to food, atypical solvent would be water and typical seed materials would be oneor more crystals of sugar or one or more crystals of salt.

Notwithstanding that the numerical ranges and parameters setting forththe broad scope of the present teachings are approximations, thenumerical values set forth in the specific examples are reported asprecisely as possible. Any numerical value, however, inherently containscertain errors necessarily resulting from the standard deviation foundin their respective testing measurements. Moreover, all ranges disclosedherein are to be understood to encompass any and all sub-ranges subsumedtherein. For example, a range of “less than 10” can include any and allsub-ranges between (and including) the minimum value of zero and themaximum value of 10, that is, any and all sub-ranges having a minimumvalue of equal to or greater than zero and a maximum value of equal toor less than 10, e.g., 1 to 5. In certain cases, the numerical values asstated for the parameter can take on negative values. In this case, theexample value of range stated as “less than 10” can assume negativevalues, e.g. −1, −2, −3, −10, −20, −30, etc.

While the present teachings have been illustrated with respect to one ormore implementations, alterations and/or modifications can be made tothe illustrated examples without departing from the spirit and scope ofthe appended claims. For example, it will be appreciated that while theprocess is described as a series of acts or events, the presentteachings are not limited by the ordering of such acts or events. Someacts may occur in different orders and/or concurrently with other actsor events apart from those described herein. Also, not all processstages may be required to implement a methodology in accordance with oneor more aspects or embodiments of the present teachings. It will beappreciated that structural components and/or processing stages can beadded or existing structural components and/or processing stages can beremoved or modified. Further, one or more of the acts depicted hereinmay be carried out in one or more separate acts and/or phases.Furthermore, to the extent that the terms “including,” “includes,”“having,” “has,” “with,” or variants thereof are used in either thedetailed description and the claims, such terms are intended to beinclusive in a manner similar to the term “comprising.” The term “atleast one of” is used to mean one or more of the listed items can beselected. Further, in the discussion and claims herein, the term “on”used with respect to two materials, one “on” the other, means at leastsome contact between the materials, while “over” means the materials arein proximity, but possibly with one or more additional interveningmaterials such that contact is possible but not required. Neither “on”nor “over” implies any directionality as used herein. The term“conformal” describes a coating material in which angles of theunderlying material are preserved by the conformal material. The term“about” indicates that the value listed may be somewhat altered, as longas the alteration does not result in nonconformance of the process orstructure to the illustrated embodiment. Finally, “exemplary” indicatesthe description is used as an example, rather than implying that it isan ideal. Other embodiments of the present teachings will be apparent tothose skilled in the art from consideration of the specification andpractice of the disclosure herein. It is intended that the specificationand examples be considered as exemplary only, with a true scope andspirit of the present teachings being indicated by the following claims.

Terms of relative position as used in this application are defined basedon a plane parallel to the conventional plane or working surface of aworkpiece, regardless of the orientation of the workpiece. The term“horizontal” or “lateral” as used in this application is defined as aplane parallel to the conventional plane or working surface of aworkpiece, regardless of the orientation of the workpiece. The term“vertical” refers to a direction perpendicular to the horizontal. Termssuch as “on,” “side” (as in “sidewall”), “higher,” “lower,” “over,”“top,” and “under” are defined with respect to the conventional plane orworking surface being on the top surface of the workpiece, regardless ofthe orientation of the workpiece.

1. A method for printing an edible confection having a three-dimensionalcrystalline structure, comprising: printing a liquid first layer ofmaterial with a printer onto a second layer of material having a crystalstructure to form a plurality of walls, wherein each of the plurality ofwalls physically contacts the second layer of material and extends fromthe second layer of material at an angle; processing the printed liquidfirst layer to solidify the plurality of walls; and printing a liquidthird layer of material with the printer onto the second layer ofmaterial to form a ceiling that physically contacts the plurality ofwalls to form a plurality of non-random cavities within the confection,wherein the ceiling comprises a surface that intersects a surface of thesecond layer of material at an angle.
 2. The method of claim 1, furthercomprising: cooling the liquid first layer of material prior to printingthe liquid third layer; using the second layer as a crystal seed layerduring the cooling of the liquid first layer of material, wherein thefirst layer crystallizes with the crystal structure during cooling;cooling the liquid third layer of material; and using the first layer asa crystal seed layer during the cooling of the third layer of material,wherein the third layer crystallizes with the crystal structure duringcooling.
 3. The method of claim 1, further comprising dispensing afilling into the plurality of non-random cavities within the confection.4. The method of claim 1, wherein the ceiling is a first ceiling and themethod further comprising: dispensing a first filling into a firstcavity; dispensing a second filling that is different from the firstfilling into a second cavity; and printing a second ceiling over thefirst cavity and the second cavity to seal the first filling into thefirst cavity and to seal the second filling into the second cavity. 5.The method of claim 1 wherein the first layer, the second layer, and thethird layer each comprises chocolate, and the method further comprises:printing a plurality of chocolate first walls, wherein each first wallhas a first thickness; printing a plurality of chocolate second walls,wherein each second wall has a second thickness that is greater than thefirst thickness; printing a plurality of chocolate ceilings, wherein atleast one of the plurality of chocolate ceilings contacts the pluralityof chocolate first walls and at least one of the plurality of chocolateceilings contacts the plurality of chocolate second walls, wherein theplurality of first walls, the plurality of second walls, and theplurality of ceilings form the plurality of non-random cavities withinthe confection.
 6. The method of claim 5, further comprising forming anouter shell that seals the plurality of cavities within the confection.7. The method of claim 6, wherein subsequent to the formation of theouter shell, the plurality of cavities do not include a solid or aliquid filling and remain filled only with gas.
 8. The method of claim1, further comprising: filling the plurality of cavities with a gascomprising at least one of methyl butanoate, ethyl butanoate, methylhexanoate, ethyl hexanoate, β-damascenone, 2-furfurylthiol,2-isobutyl-3-methoxypyrazine, guaiacol, 2,3-butanedione,4-hydroxy-2,5-dimethyl-3(2H)-furanone, and combinations thereof; andforming an outer shell that seals the gas within the plurality ofcavities within the confection.
 9. The method of claim 1, furthercomprising: printing the liquid first layer of material using adrop-on-demand printer; and printing the liquid third layer of materialusing the drop-on-demand printer.
 10. The method of claim 1, furthercomprising: printing the liquid first layer of material using anextrusion printer; and printing the liquid third layer of material usingthe extrusion printer.
 11. A confection, comprising: a plurality ofchocolate walls, wherein each chocolate wall has a thickness of between5 micrometers and 10 millimeters; a plurality of non-random cavitiesformed at least partly by the plurality of chocolate walls; and an outershell that seals the plurality of non-random cavities within theconfection.
 12. The confection of claim 11, further comprising aplurality of chocolate ceilings that intersect the plurality of walls toprovide a plurality of non-random cavities, wherein each chocolateceiling has a thickness of between 5 micrometers and 10 millimeters. 13.The confection of claim 12, further comprising a filling that at leastpartially fills the plurality of cavities.
 14. The confection of claim12, wherein the plurality of cavities is a first plurality of cavitiesand the confection further comprises: a second plurality of cavities; afirst filling that at least partially fills, and is sealed within, thefirst plurality of cavities; and a second filling that at leastpartially fills, and is sealed within, the second plurality of cavities,wherein the first filling is different from the second filling.
 15. Theconfection of claim 12, wherein the plurality of chocolate walls is afirst plurality of chocolate walls having a first thickness, and theconfection further comprises a second plurality of chocolate wallshaving a second thickness, wherein the second thickness is greater thanthe first thickness.
 16. The confection of claim 12, wherein: theplurality of walls is a first plurality of walls; the plurality ofnon-random cavities is a first plurality of non-random cavities having afirst width; the first plurality of walls and the first plurality ofnon-random cavities provide a first confection layer; the confectionfurther comprises: a second plurality of walls; a second plurality ofnon-random cavities having a second width that is different from thefirst width; the second plurality of walls and the second plurality ofnon-random cavities provide a second confection layer.
 17. Theconfection of claim 16, wherein: the plurality of first walls has afirst thickness; the plurality of second walls has a second thickness;and the first thickness is different than the second thickness.
 18. Theconfection of claim 17, further comprising a ceiling that separates thefirst confection layer from the second confection layer.
 19. Theconfection of claim 11, further comprising a floor that contacts theouter shell and seals the plurality of non-random cavities within theconfection, wherein: the plurality of chocolate walls extend from thefloor to the outer shell; and each cavity connects to both the floor andthe outer shell within the confection.
 20. The confection of claim 11,further comprising: a gas within the plurality of non-random cavities,wherein the gas comprises at least one of methyl butanoate, ethylbutanoate, methyl hexanoate, ethyl hexanoate, β-damascenone,2-furfurylthiol, 2-isobutyl-3-methoxypyrazine, guaiacol,2,3-butanedione, 4-hydroxy-2,5-dimethyl-3(2H)-furanone, and combinationsthereof.